Professional Documents
Culture Documents
REPLACEMENT OF CEMENT
BY
MUNEEB-UL-HASSAN 2015-UET-CCET-CIVIL-23
SUPERVISOR
REPLACEMENT OF CEMENT
BY
MUNEEB-UL-HASSAN 2015-UET-CCET-CIVIL-23
_____________________ _______________________
Engr. Jamil Ahmad External Examiner
Research Advisor/ _____________________
Internal Examiner Prof. Dr.Kh. Adeel
HOD Civil Engineering
ii
ABSTRACT
Self-Compacting Concrete with ultimate aim to achieve the desired properties in fresh
and hardened state. The parameters studied include filling ability, passing ability, strength
development, resistance to water absorption and acid attack. The primary aim of this
study is to explore the feasibility of developing SCC made by partially replacing cement
with bentonite clay. This study was made to evaluate the feasibility of using Bentonite, a
naturally occurring pozzolan, with an artificial pozzolanic material, in single component
which is used in hydrated form in this research. The parameters are tested at different
specified ages in accordance with EFNARC and ASTM standards.
Test results revealed that mixes associated with bentonite showed slightly lower
workability and passing ability than control mix. Test results revealed that mixes
associated with bentonite, showed a little lower compressive and flexural strength than
control mix. Furthermore, the addition of bentonite in replacement mode reduces the
permeability of the hardened SCC and thus enhances its resistance against sulfate attack.
The cost comparison shows 5% reduction by incorporating 6% bentonite to attain 25 MPa
strength against normal SCC mix.
iii
ACKNOWLEDGEMENT
Thanks to Almighty Allah, the most beneficent and most merciful, whose blessing gave
us the strength and courage to complete this research work.
We would like to express our gratitude to everyone who has contributed to this study.
Special thanks are extended to: Dr. Khawaja Adeel Tariq for his assistance and supports
to us in our research work. We are significantly thankful to Supervisor Engr. Jamil
Ahmad for his valuable suggestions and counseling.
We must not forget the supporting role of laboratory staff at CCET, Gujranwala who
provided technical assistance and cooperation during the execution of the research work.
Finally, we pay our deepest gratitude with deepest sense of respect to our parents, for
their eternal support, encouragement, prayers and patience.
iv
TABLE OF CONTENTS
ACKNOWLEDGEMENT ........................................................................................ iv
ABBREVATIONS ......................................................................................................xii
Chapter 1
INTRODUCTION ........................................................................................................ 1
1.1 BACKGROUND OF SELF-COMPACTING
CONCRETE ................................................................................................ 1
1.2 SECONDARY RAW MATERIALS ......................................................... 3
1.3 POZZOLAN ................................................................................................ 3
1.3.1 Natural Pozzolan ................................................................................... 3
1.3.2 Artificial Pozzolan ................................................................................. 3
1.4 MECHANISM OF POZZOLANIC REACTION .................................... 4
1.5 BENTONITE ............................................................................................... 4
1.6 DEPOSITS OF BENTONITE IN KPK .................................................... 5
1.6.1 Chasma Wali Bentonite ........................................................................ 5
1.6.2 Karak Bentonite .................................................................................... 5
1.6.3 Garhi Chandan Bentonite .................................................................... 5
1.6.4 Jehangira Bentonite .............................................................................. 5
1.7 NEED FOR THIS RESEARCH ................................................................ 6
1.8 SCOPE ......................................................................................................... 7
1.9 OBJECTIVE ............................................................................................... 7
1.10 THESIS CHAPTERS ................................................................................. 8
CHAPTER 2
LITERATURE REVIEW .......................................................................................... 9
v
2.1 DEVELOPMENT OF SELF-COMPACTING
CONCRETE ................................................................................................ 9
2.2 BASIC PRINCIPLES AND REQUIREMENTS OF
SCC............................................................................................................. 10
2.3 FILLING ABILITY .................................................................................. 11
2.4 PASSING ABILITY ................................................................................. 11
2.5 SEGREGATION RESISTANCE ............................................................ 11
2.6 RANGES OF THE QUANTITIES OF THE
CONSTITUENT MATERIALS FOR SCC ............................................ 12
2.7 MIX DESIGN FOR SCC.......................................................................... 14
2.8 SECONDARY RAW MATERIALS ....................................................... 16
2.9 BENTONITE ............................................................................................. 16
CHAPTER 3
EXPERIMENTAL PROGRAM............................................................................ 18
3.1 INTRODUCTION..................................................................................... 18
3.2 MATERIAL USED ................................................................................... 18
3.2.1 Cement ................................................................................................. 18
3.2.2 Fine Aggregates ................................................................................... 19
3.2.3 Coarse Aggregate ................................................................................ 21
3.2.1 Water .................................................................................................... 22
3.2.1 Filler ..................................................................................................... 22
3.2.1 Admixture ............................................................................................ 23
3.2.1 Bentonite .............................................................................................. 24
3.3 FINENESS MODULUS ........................................................................... 25
3.4 SPECIFIC GRAVITY .............................................................................. 25
3.5 WATER ABSORTION ............................................................................ 25
3.6 SCC TRAIL MIXES ................................................................................. 26
3.7 TRIAL SAMPLING RESULTS .............................................................. 27
3.8 FINAL MIX PROPORTIONS................................................................. 28
3.9 CASTING SCHEDULE ........................................................................... 29
vi
3.10 CASTING AND CURING OF MIXES .................................................. 30
3.11 SELF COMPACTABLITY TEST ON SCC ......................................... 30
3.11.1 Slump Flow Test ................................................................................. 30
3.11.2 L-Box Test........................................................................................... 32
3.12 HARDENED PROPERTIES TESTING .............................................. 34
3.12.1 Compressive Strength ........................................................................ 34
3.12.2 Flexural Strength ............................................................................... 36
3.12.3 Water Absorption Test ...................................................................... 37
3.12.4 Acid Attacks ....................................................................................... 38
3.13 STRESS STRAIN BEHAVIOR OF CYLINDERS
UNDER COMPRESSIVE LOADING .................................................. 40
CHAPTER 4
RESULTS AND DISCUSSION ............................................................................. 41
4.1 FRESH PROPERTIES RESULTS ....................................................... 41
4.1.1 Slump Flow Test ................................................................................. 41
4.1.2 L-Box Test Results ............................................................................. 43
4.2 HARDENED PROPERTIES RESULTS .............................................. 44
4.2.1 Compressive Strength ........................................................................ 44
4.2.2 Flexural Strength ............................................................................... 47
4.2.3 Water Absorption Test ...................................................................... 50
4.2.4 Acid Attacks ....................................................................................... 51
4.3 STRESS STRAIN BEHAVIOR OF CYLINDERS
UNDER COMPRESSIVE LOADING .................................................. 53
4.4 COST COMPARISON ........................................................................... 54
CHAPTER 5
CONCLUSION AND RECOMMENDATION ................................................ 55
5.1 CONCLUSION ....................................................................................... 55
5.2 RECOMMENDATIONS........................................................................ 55
REFERENCES ................................................................................................................. 57
vii
LIST OF TABLE
Table 2.1 Test Methods To Evaluate The Workability Properties Of Scc(Efnarc, 2002)
............................................................................................................................................ 12
Table 4.6 Hcl & H2SO4 Avg. Loss Of Weight Of Different Mixes ............................... 51
viii
LIST OF FIGURES
Figure 3.6 L-Box Apparatus Utilized To Find Filling And Passing Ability ................. 33
Figure 3.8 Compressive Strength Test In Progress ......... Error! Bookmark not defined.
ix
Figure 4.4 Average Compressive Strength Of Scc Specimens At All Ages .................. 46
Figure 4.5 Comparison Of Rate Of Gain Of Compressive Strength For All Mixes ....... 47
Figure 4.9 Acid Effect On The Loss Of Weight For Different Mixes ............................ 52
x
ABBREVATIONS
BC Bentonite Clay
C3 S Tri-Calcium Silicate
C2 S Di-Calcium Silicate
C3S2H3 Calciumsilicatehydrate
xi
CHAPTER 1
INTRODUCTION
SCC was developed in Japan in the late 1980‟s to be mainly used for highly congested
reinforced structures in seismic regions (Bouzoubaa and Lachemi, 2001). SCC can be
described as a high performance material which flows under its own weight without
requiring vibrators to achieve consolidation by complete filling of formworks even when
access is hindered by narrow gaps between reinforcement bars (Zhu et al, 2001). Since its
inception, it has been widely used in large construction in Japan (Okamura and Ouchi,
2003).SCC can also be used for filling non-congested sections to accelerate the progress
of construction without mitigating mechanical properties and durability that can result
from segregation and bleeding (K. H. Khayat, 1999). Recently, this concrete has gained
wide use in many countries for different applications and structural configurations
(Bouzoubaa and Lachemi, 2001).
1
Europe, for both site and precast concrete work. It has proved beneficial economically
because of a number of factors, noted below(EFNARC, 2002):
1. Faster construction
2. Reduction in site manpower
3. Better surface finisher
4. Easier placing
5. Improved durability
6. Greater freedom in design
7. Thinner concrete sections
8. Reduced noise levels,
9. Absence of vibration safer working environment
10. Safer working environment
The method for achieving workability involves not only high deformability of paste or
mortar, but also resistance to segregation between coarse aggregate and mortar when the
concrete flows through the confined zone of reinforcing bars(Okamura and Ouchi, 2003).
Homogeneity of SCC is its ability to remain unsegregated during transport and placing.
High flow ability and high segregation resistance of SCC are obtained by;
To produce SCC, the major work involves designing an appropriate mix proportion and
evaluating the properties of the concrete thus obtained. In practice, SCC in its fresh state
shows high fluidity, self-compacting ability and segregation resistance, all of which
contribute to reducing the risk of honeycombing of concrete (Su et al, 2001). With these
good properties, the SCC produced can greatly improve the reliability and durability of
the reinforced concrete structures. In addition, SCC shows good performance in
compressive strength test and can fulfill other construction needs because its production
has taken into consideration the requirements in the structural design.
2
1.2 SECONDARY RAW MATERIALS
Secondary raw materials are pozzolanic or inert powders which usually replace a part of
cement and are used to modify / improve the properties of concrete which may include
the control of early heat evolution, reduction in shrinkage, better packing, optimization of
flow, enhancement of strength, improvement of microstructure, economy and the
durability of cement based systems. In the literature secondary raw materials have been
mentioned in a variety of ways like supplementary cementitious materials, waste
materials and fillers.
1.3 POZZOLAN
The natural pozzolans include volcanic ashes, opaline shales and cherts, calcined
diatomaceous earth, and burnt clays. According to (ASTM C 618), these materials are
described as Class N type pozzolans. These materials are usually processed for producing
pozzolan which involves drying, grinding.
These are the by-products of industries producing them. For example, fly ash is the most
common pozzolan in use. These materials may or may not require processing before use
(Metha, 2006).According to (ASTM C 618), these pozzolans are termed as Class C or
Class F type pozzolans depending upon the silica content.
3
1.4 MECHANISM OF POZZOLANIC REACTION
When Ordinary portland cement is mixed with water, forms calcium silicate hydrate
(CSH) gel along with calcium hydroxide and ettringite and containing concentrations of
calcium silicate hydrate in a metastable condition(Neville, 2000). The reaction between
calcium hydroxide and pozzolan is called the pozzolanic reaction. The technical
significance of the pozzolanic reaction is threefold. First, the reaction is slow. Second, the
reaction is lime consuming instead of lime producing, which has an important bearing on
the durability of the hydrated paste to acidic environments. Third, pore size distribution
has shown that the reaction products are very efficient in filling up large capillary space,
thus improving the strength and impermeability of the system (Metha, 2006)
1.5 BENTONITE
Bentonite is naturally occurring absorbent pozzolanic clay and is commonly divided into
sodium Bentonite (high swelling), calcium Bentonite (low swelling), aluminum Bentonite
and potassium Bentonite. Typically high swelling Bentonites have a frothy texture caused
by its alternate swelling and drying, whereas low swelling types have a cracked
appearance. Therefore the properties of pastes, mortars and concrete vary accordingly,
depending upon the type of Bentonite used. The Bentonite used in the present study is
4
Potassium or K-Bentonite. The potassium Bentonite is potassium rich illitic clay formed
from alternation of volcanic ash, where illite is a nonexpanding mineral and is either a
phyllosilicate (silicate mineral) or layered alumino silicate.
The Chashma Wali Bentonite deposits are situated 2 km due north-northwest of Jalbi
village, Peshawar(Ahmed, 1992).
The Karak Bentonite deposits are situated 112 km due south of Kohat town and about 56
km northeast of Bannu town. The deposits are spread over an area of 18 Sq. km (Ahmed,
1992).
These deposits are situated along the Shingle road and about half kilometer south of Garhi
Chandan village. The deposits are spread over an area of 12 Sq. km(Badshah, 2003).
The Jehangira Bentonite deposits are situated at 33o59‟56” latitude and 72o12‟47”
longitude in Survey of Pakistan topographic sheet 43 C/1. River Kabul truncates these
deposits in the south(Badshah, 2003). Bentonite used in this research work was taken
from Jehangira.
5
Figure 1.1 Jehangira Bentonite Deposits
.
1.7 NEED FOR THIS RESEARCH
We have a vibrant construction industry at domestic level, but now is the time to integrate
contemporary concepts into our standard building products and methods to make buildin
gs cost-effective, sustainable and environmentally friendly. The primary objective of this
research was to assess the possibility of using Bentonite as pozzolan in self-compacting
concrete.
6
1.8 SCOPE
The scope of this research was to develop SCC incorporating secondary raw material by
partially replacing cement with bentonite clay to determine the strength characteristics
and durability of such concrete.
1.9 OBJECTIVE
To study the properties of fresh and hardened SCC with and without addition of
bentonite.
To study the cost effect of concrete with and without addition of bentonite as partial
replacement of cement.
7
1.10 THESIS CHAPTERS
CHAPTER DETAILS
8
CHAPTER 2
LITERATURE REVIEW
The idea of a concrete mixture that can be consolidated into every corner of a formwork,
purely by means of its own weight and without the need for vibration, was first
considered in 1983 in Japan, when concrete durability, constructability and productivity
became a major topic of interest in the country. During this period, there was a shortage
of number of skilled workers in Japan which directly affected the quality of the concrete.
Okamura proposed the use of SCC in 1986. Studies to develop SCC, including a
fundamental study on the workability of concrete, were carried out by Ozawa and
Maekawa at the University of Tokyo, and by 1988 the first practical prototypes of SCC
were produced. By the early 1990‟s Japan started to develop and use SCC and, as of
2000, the volume of SCC used for prefabricated products and ready-mixed concrete in
Japan was over 520,000 yard3 (i.e. 400,000 m3)(Ouchi et al., 2003).
In 1996, several European countries formed the “Rational Production and Improved
Working Environment through using SCC” project in order to explore the significance of
published achievements in SCC and develop applications to take advantage of the
potentials of SCC. Since then, SCC has been used successfully in a number of bridges,
walls and tunnel linings in Europe(Ouchi et al., 2003)
9
During the last three years, interest in SCC has grown in the United States, particularly
within the precast concrete industry. SCC has been used in several commercial projects
(Ozyildirim, 2003): (Ouchi et al., 2003). Numerous research studies (K. H. Khayat,
1999); (Chan at al, 2003), have been conducted recently with the objective of developing
raw material requirements, mixture proportions, material requirements and
characteristics, and test methods necessary to produce and test SCC.
The latest studies related to SCC focused on improved reliability and prediction of
properties, production of a dense and uniform surface texture, improved durability, and
both high and early strength permitting faster construction and increased productivity
(Khayat et al, 2004); (Chan at al, 2003); (Sonebi, 2003)).
With regard to its composition, SCC consists of the same components as conventionally
vibrated normal concrete, which are cement, aggregates, water, additives and admixtures.
However, high volume of superplasticizer for reduction of the liquid limit and for better
workability, the high powder content as “lubricant” for the coarse aggregates, as well as
the use of viscosity-agents to increase the viscosity of the concrete have to be taken into
account (Dehn et al, 2000) Figure 2.1 shows the basic principles for the production of
SCC
10
Researchers have employed the following methods to achieve workability of SCC
(Okamura, H. and Ozawa, K., 1995);
1. Limited aggregate content (coarse aggregate 50% of the concrete volume and sand
40% of the mortar volume),
A concrete mix can only be classified as SCC if the requirements for all the following
three workability properties are fulfilled (EFNARC, 2002),
1. Filling ability,
3. Segregation resistance.
It is the ability of SCC to flow into all spaces within the formwork under its own weight.
Tests, such as slump flow, V-funnel etc., are used to determine the filling ability of fresh
concrete.
It is the ability of SCC to flow through tight openings, such as spaces between steel
reinforcing bars, under its own weight. Passing ability can be determined by using U-box,
L-box, Fill-box, and J-ring test methods.
The SCC must meet the filling ability and passing ability with uniform composition
throughout the process of transport and placing.
11
The test methods to determine the workability properties of SCC are presented in Table
2.1.Test methods to evaluate the workability properties of SCC (EFNARC, 2002)
Table 0.1 Test Methods To Evaluate The Workability Properties Of SCC(EFNARC 2002)
Test methods
FOR SCC.
Typical ranges of proportions and quantities of the constituent materials for producing
SCC are given below:
1. Water content: 170 to 176 kg/m3 (Su et al., 2001), It should not exceed 200 kg/m3
(EFNARC, 2002).
3. Total powder content (i.e., cement + filler): 400 to 600 kg/m3(EFNARC, 2002).
4. Dosage of superplasticizer: 1.8% of the total powder content (by mass) (Su et al,
2001). However, the recommended dosage varies from product to product.
12
6. Coarse aggregate contents: 28 to 35% by volume of the mix, i.e., 700 to 900
kg/m3 of concrete (EFNARC, 2002),
7. The sand content balances the volume of other constituents. The sand content
should be greater than 50% of the total aggregate content (Munn, 2003). Sand
ratio (i.e. volume ratio of fine aggregate to total aggregate) is an important
parameter in SCC and the rheological properties increase with an increase in sand
ratio. Sand ratio should be taken in the range of 50 to 57% (Su et al, 2001)and
2. T50cmslumpflow s 2 5
3. J-ring mm 0 10
4. V-funnel s 6 12
7. U-box (h2-h1) mm 0 30
8. Fill-box % 90 100
10. Orimet s 0 5
13
2.7 MIX DESIGN FOR SCC
A flow-chart describing the procedure for design of SCC mix is shown in Figure 2.2
A simple mix proportioning system for SCC (Okamura, H. and Ozawa, K., 1995). The
coarse and fine aggregate contents are fixed so that workability can be achieved easily by
adjusting the water/powder ratio and super plasticizer dosage only. The mix design
procedure is as follows:
1. The coarse aggregate content (all particles larger than 4 mm and smaller than
maximum size of aggregate) is fixed in the range of 50 to 60% of the solid volume
or 28 to 35% of the concrete volume or 700 to 900 kg per cubic meter of concrete.
2. The fine aggregate content (all particles larger than 0.125 mm and smaller than 4
mm) is fixed in the range of 40 to 50% of the mortar volume.
3. The water/powder ratio is assumed in the range of 0.8 to 1.0 (by volume),
depending on the properties of the powder (i.e. cement and filler having particles
smaller than 0.125 mm).
14
4. The superplasticizer dosage and the final water/powder ratio are determined
through trial mixes so as to ensure workability using U-flow, slump-flow and V-
funnel tests. Target values are U-flow of 0 to 30 mm, slump-flow of 650 to 800
mm, and V- funnel time of 6 to 12 seconds.
A simple mix design method for SCC has been proposed by (Su et al, 2001)
Compared with the method developed by the Japanese Ready-Mixed Concrete
Association (JRMCA), this method is simple, easy for implementation and less
time- consuming, requires a small quantity of binder and saves cost. This method
consists of the following steps:
3. Determination of the filler content and water content for the selected
water/powder ratio and assumed air content, using the total absolute volume
equation.
6. Preparation of the trial mixes and carrying out tests for determining the properties
of SCC.
15
2.8 SECONDARY RAW MATERIALS
Researchers reported that when mineral admixtures are added, three effects can be
quantified including dilution, heterogeneous nucleation (physical) and pozzolanic
reaction (chemical) depending on the amount and solubility of amorphous silica, where
heterogeneous nucleation is a physical process leading to a chemical activation of
hydration of cement such that mineral admixture particles act as nucleation centers for the
hydrates thus enhancing cement hydration. Further,(Rizwan et al, 2006) that in addition to
cement grains, secondary raw material particles also adsorb superplasticizer and water.
2.9 BENTONITE
In Pakistan, research carried out on the use of bentonite clay as replacement of cement is
given as under;
It was found out the reactivity index of mortar cubes containing Jehangira bentonite as
replacement of cement. He concluded that 40 per cent replacement of bentonite in mortar
and 25 per cent replacement in concrete yielded satisfactory results when used AS SUCH
(without any heat treatment). Modulus of rupture of bentonite concrete beam was less
than control beam and decreased further as the bentonite replacement increased. He also
concluded that 11 per cent of the concrete cost can be saved by replacing 25 per cent of
bentonite with cement (Hassan et al., 2003).
16
addition reduces strength drastically. Sulfate resistance of concrete increases as the
pozzolana replacement increases. At 20 per cent of bentonite replacement, sulphate
resistance of mortar in 2 per cent sulphate solution is maximum (Badshah, 2003).
It was found out the reactivity of Jehangira bentonite when used in AS SUCH form and
calcined at 500oC and 900oC. He concluded that Jehangira bentonite is more reactive
when used AS SUCH than calcined at 500oC and 900oC. He also concluded that
soundness of concrete is better in the presence of bentonite and sulphate resistance is
maximum at 30 per cent substitution of bentonite. Porosity of concrete was found out to
be minimum at 30 per cent substitution of bentonite (Iqbal, 2004).
17
CHAPTER 3
EXPERIMENTAL PROGRAM
3.1 INTRODUCTION
In this chapter details of selecting an appropriate SCC mix for evaluating its performance
in phrases of strength and durability are described. For choosing a suitable mix five trial
mixes had been taken into consideration through various their mix parameters, consisting
of quantity of cement, filler, superplasticizer, satisfactory aggregate, maintaining the
water/powder ratio constant. Each trial mix was tested for self-compatibility and
compressive strength. The trial tests are performed on control mix specimens to meet the
characteristics of SCC without incorporating bentonite clay. The mix with highest self-
compatibility and compressive strength was selected for further investigation
incorporating bentonite. Details of procedure adopted in preparing trial sample, material
used and different test methods are discussed.
3.2.1 Cement
In this experimental work, type 1 ordinary Portland cement was used throughout from one
of the most popular brand of OPC “ASKARI CEMENT” Pakistan. The physical
properties and chemical composition of OPC are tabulated in table 3.1.
18
Table 0.1 Physical Properties And Chemical Composition Of OPC
K2O 1.00
Locally available Chenab sand was utilized in this experimental work. Sieve analysis of
the sand graded between (No.4) sieve and (No.100) sieve was carried out in concrete
laboratory of CCET according to ASTM C33. The value of fineness modulus of sand was
found to be 2.88.
19
Table 0.2 Grading Of Fine Aggregates
100
90
80
70
60
% Passing
50
40
30
20
10
0
10 1 0.1
Sieve Sizes
20
3.2.3 COARSE AGGREGATE
Locally available Margala Crush was utilized in this experimental work. Crushed stone
having maximum size of 19 mm (3/4 in) was used as coarse aggregate. Sieve analysis was
performed in laboratory of CCET according to ASTM C33. The value of fineness
modulus of stone was found to be 3.27.
19 0 0 0 100 100
21
100
90
80
70
60
% Passing
50
40
30
20
10
0
100 10 1
Sieve Sizes
3.2.4 Water
The water utilized for mixing the ingredients of SCC was ordinary tap water of concrete
laboratory of CCET Gujranwala.
3.2.5 Filler
Fly ash an artificial pozzolana, of class F was used as a filler to provide workability to
SCC. Its specific gravity is 2.10. Its chemical composition is tabulated below in Table
3.4.
22
Table 0.4 Chemical Composition Of Fly Ash
SiO2+AL2O3+FE2O3 88.21
P2O5 6.22
CaO 4.42
Cl 0.011
SO3 0.51
Na2O 0.51
3.2.6 Admixture
PROPERTIES SP 437
pH 7.5
23
Standards
AASHTO M-194
3.2.7 Bentonite
Bentonite clay obtained from Jehangira was used as pozzolan. Los Angles abrasion
machine was used for grinding of bentonite clay. After grinding the sample was sieved
through sieve No.200 and the sieved sample was used for developing different mixes. The
physical properties of bentonite is tabulated in Table 3.5.
Properties Bentonite
Liquid Limit 35
Plastic Limit 29
24
3.3 FINENESS MODULUS
The fineness modulus was calculated as the sum of cumulative percentages retained on
different sieves divided by 100. The value of fineness modulus of sand was 2.87 and the
value fineness modulus of stone was 3.27.
The specific gravity of sand was calculated in keeping with ASTM C 128-79. The
specimen of 1 Kg was soaked for 24 in water. The specimen end up taken out of water
after 24 hours and was spread on a nonabsorbent floor. It was stirred time and again to at
ease uniform drying. Pycnometer become in part full of water and 500 g of saturated
ground dry fine aggregates have been added in it (S). Extra water was introduced inside
the pycnometer to about 90% capacity. Pycnometer come to be inverted, rolled and
agitated to cast off air bubbles. Total weight of pycnometer, specimen and water turn out
to be decided (C). The fine aggregates were eliminated from pycnometer, dried. They
have been dried at 100 C and then weighed (A). Pycnometer become full of water and its
weight became recorded (B). Bulk specific gravity was calculated with the aid of the
subsequent equation.
The specific gravity of sand and aggregate was 2.61 and 2.72.
The water absorption of fine aggregate and course aggregate was found to be 1.07% and
1.3%. ASTM C 128-01 procedure was adopted to calculate water absorption. Water
absorption of aggregates was determined by the same procedure used to calculate the
specific gravity as above but calculated by using this formula.
25
3.6 SCC TRAIL MIXES
A number of trials had been made to develop SCC. The mixes were prepared via varying
the content material of components. For each mix, a constant water/powder ratio, two
level of filler 20 to 25 kg/m3, two level of fine to coarse combination ratio 1 and 1.1 by
using mass, two ranges of cement content and level of superplasticizer 437 became saved
1.8%.Ratios of different constituent of SCC utilized in trial mixes are given in Table 3.7.
Powder
(Kg/m3) (Kg/m3)
26
3.7 TRIAL SAMPLING RESULTS
The results of the five trial mixes of SCC are shown in table 3.8
T50cm L-box***
Trial Flow table*
Slump flow ** (H2/H1)
Mixes (mm) 7 Days
(sec)
* Slump flow value should be in range from 650 60 800 mm(EFNARC, 2002)
The trial mixes of SCC control mix were prepared keeping in view (EFNARC, 2002)
guidelines. The workability and compressive strength of trial mixes are shown in table 3. .
The values of compressive strength are of 7 days age. Trial mix TM5 achieved the
maximum compressive strength of 14 MPA with workability greater than other trial
mixes which satisfies the self-compatibility criteria. TM5 was considered for further
investigation by partially replacing cement with bentonite.
27
3.8 FINAL MIX PROPORTIONS
Quantities (kg/m3)
Constituent Materials
Mix 1 Mix 2 Mix 3 Mix 4 Mix 5
Fly ash 25 25 25 25 25
Bentonite 0 30 60 90 120
28
3.9 CASTING SCHEDULE
Five different mixes were prepared by varying bentonite clay to check its effect on
physical parameters of SCC
For compressive strength a total of 45 cylinder were cast and tested at 7, 28, 56 days.
For flexural strength a total of 30 beams were cast and tested at 28, 56 days.
100x100x510 mm beams were used for flexural test (by center point loading).
For durability test such as water absorption and acid attacks a total no of 45 cubes were
casted. 100x100x100 cubes were used for the tests. Water absorption cubes were tested at
28 days. Acid attacks cubes were tested after 56 days immersion in acid tanks.
ASTM C 39
ASTM C 293M
ASTM C 642-97
ASTM C 642-97
29
3.10 CASTING AND CURING OF MIXES
Throughout casting of the mixes molds had been nicely oiled for clean demolding. No
vibrator was used because SCC flows under its own weight. After casting the specimens
had been covered with plastic sheet to avoid loss of water. After 24 hours of casting
specimens were demolding and transferred to the curing tank. After casting all samples of
SCC have been cured in curing tank at room temperature till detailed age of testing. Tap
water of concrete laboratory at CCET was used for curing purpose.
The slump flow test is performed to check the workability of concrete. This test is carried
out according to (EFNARC, 2002) guidelines. The dimension of the cone used was same
as that of slump test (i.e. 100 mm top diameter, 200 mm bottom diameter, 300 mm
height). In this test, the horizontal flow of concrete was measured when a slump cone
filled with concrete was lifted upwards on a base plate. The concrete was allowed to flow
on base plate, and the flow of concrete was measured when the concrete stop to flow.
Time taken to reach horizontal flow of 500 mm in diameter was also recorded for t 50 test
(EFNARC, 2002).
30
Figure 3.3 Base Plate With Abrams Cone
31
3.11.2 L-Box Test
L-box test accesses the flow of concrete, it accesses filling and passing ability of concrete
and extreme lack of segregation can be detected visually. An apparatus of L form became
required for this test. The dimension of L-box givens by standards were adopted proven
in Figure 3.9. To discover the passing capability concrete is allowed to pass via a 700 mm
lengthy and 200 mm wide channel after passing via 3 equally spaced (41mm) 12 mm
steel bars of channel. The height of concrete was measured at the end of channel and just
before the steel bars. The ratio of heights of concrete at the end and beginning of channel
gives the blocking ratio.
32
Figure 3.6 L-Box Apparatus Utilized To Find Filling and Passing Ability
Procedure for accomplishing the L-box test consists of the following steps:
1. The L-field is guide on a level horizontal base and close the gate between the
vertical and horizontal sections
3. When motion has ceased, measure the vertical distance, at the stop of the
horizontal segment of the L-box, among the top of the concrete and the top of the
horizontal phase of the container at three positions similarly spaced across the
width of the box.
33
4. By difference with the height of the horizontal section of the box, these three
measurements are used to calculate the mean depth of concrete as H2 mm. The
same procedure is used to calculate the depth of concrete immediately behind the
gate as H1 mm.
F=P/A
34
Figure 3.7 Compressive Testing On Specimen
35
3.12.2 Flexural Strength
This test method was carried on beams of 100x100x510mm. Specimen were prepared in
accordance with the specifications of ASTM C 192M. Centre point loading was applied
to find the flexural strength (ASTM C293, 2016). Specimens were tested at the age of 28
and 56 days. The average of three tested beams was recorded as flexural strength or
modulus of rupture.
R=3PL/2bd2
Where P=load
L= length of beam
b= width of beam
d= depth of beam
36
3.12.3 Water Absorption Test
Test was carried on cubes of 100x100x100 mm from each mix of SCC. After 28 days of
curing, cubes were taken out of curing tank and were wiped off with a cloth to dry the
surface of cubes and transferred to the laboratory oven. The cubes were placed in oven at
a temperature of 1000 ℃ for 24-hours for oven-dry. After removal the cubes were
weighted. Then the cubes were again kept in oven for next 24 hours and again weighted.
The difference between the two weights was less than 0.5% of lesser value, which
confirmed that the cubes were completely dry(ASTM C 642).
The cubes were then again immersed in water for 48-hours. The weight of cubes was
again recorded on removal from water tank. Then again these cubes were immersed in
water for about 24 hours and after removal again weight was recorded. The deference
between the two was again less than 0.5% of lesser value, which confirmed that
maximum absorption has, taken place. Water absorption was calculated by their
difference weight after absorption (saturated weight) and oven dried weight (dry weight).
W1 =dry weight
37
Figure 3.10 Cubes Placed In Oven
Test method was adopted to find the attacks of acid on concrete. It is a durability test in
which durability is measured by measuring the resistance of specimen against acid attack.
Two high strength acids which are hydrochloric acid and sulphuric acid were used for this
purpose. Sulphuric acid is also known as the king of acids. First of all we prepared a
dilute acidic solution of 5% HCL and 5% H2SO4 and then immersed all the specimens in
to it for about 56 days. After that the acidic resistance was measured in terms of weight
loss (ASTM C 642, 2006).
38
Figure 3.11 Acid Curing For Acid Attack Test
39
3.13 STRESS STRAIN BEHAVIOR UNDER COMPRESSIVE LOADING
Stress strain curve is the graphical representation of concrete under load. It is used to find
the behavior of concrete to predict the response of concrete under sort of loading. It is
produce by plotting concrete compress strain at various interval of stress (compressive
load). The value of peak strain and modulus of elasticity are obtained.
40
CHAPTER 4
The slump flow test is used to measure the free flow of SCC without any obstruction. The
workability of various mixes of SCC are within the range distinctive with the aid of
(EFNARC, 2002). Filling ability was measured whilst concrete attain a diameter of 500
mm and time taken to reach that circle is likewise recorded and nominated as T50 cm
slump flow. The particular values obtained from slump flow test are shown in table 4.1.
The workability values for all the mixes containing different percentages of bentonite clay
are designated in figure 4.1.
Mix 2 710 4
Mix 3 690 4
*Slump flow value should be in range from 650 60 800 mm(EFNARC, 2002)
41
The results of the filling ability for all the mixes lies in range of (EFNARC, 2002)
guidelines. The decrease in value of flow was due to bentonite clay because it absorbs
water to some extent. With, the increase in percentage of bentonite in SCC flow reduces
and time taken to fill the circle of 500 mm increases due to absorption of water.
800
700
600
Slump Flow (mm)
500
400
300
200
100
Mix 1 Mix 2 Mix 3 Mix 4 Mix 5
MIX
5
4.5
4
3.5
T50 cm Time (Sec)
3
2.5
2
1.5
1
0.5
0
Mix 1 Mix 2 Mix 3 Mix 4 Mix 5
MIX
42
4.1.2 L-Box Test Results
The L-box test is proposed in (EFNARC, 2002) to find the passing ability of SCC mixes.
Concrete is allowed to pass through 700 mm long, 200 mm wide channel after passing
through three equally spaced 12 mm steel bars. The results of different mixes of SCC are
shown in table 5.2. The blocking ratio values of different mixes containing different
percentages of bentonite clay are plotted in figure 4.2.
L-box
MIX
(H2/H1)
Mix 1 0.91
Mix 2 0.89
Mix 3 0.87
Mix 4 0.85
Mix 5 0.82
From, the results above presented it is clear that bentonite absorbs some water. (Mix 1)
value of L-box test shown that it does not have much viscosity as compared to other
mixes of SCC containing different percentage of bentonite. As the blocking ratio values
nearer 0.8 may likely to have passing ability problems such as high viscosity or little
segregation.
43
1
0.95
0.9
0.85
Blocking Ratio
0.8
0.75
0.7
0.65
0.6
0.55
0.5
Mix 1 Mix 2 Mix 3 Mix 4 Mix 5
Mix
44
Table 0.3 Compressive Strength
Compressive Strength
Mix
45
35
30
25
Compressive Strength (MPa)
20
15
10
0
Mix 1 Mix 2 Mix 3 Mix 4 Mix 5
The rate of gain of strength for all mixes is almost linear as shown in figure 5.5. The
strength of mixes gradually increases due to fly ash content because it slows the hydration
reaction process so strength increases with age. At 56 days maximum strength of all
mixes are obtained.
46
35
30
Compressive Strength (MPa)
25
20
15
10
Age (Days)
Figure 4.5 Comparison Of Rate Of Gain Of Compressive Strength For All Mixes
The flexural strength of SCC was measured according to ASTM C293M. Center point
loading was used to find the flexural strength. The beams cured for 28 and 56 days are
tested. The results shows maximum flexural strength gained at 56 days age which is a
little higher than 28 days. The maximum result is of Mix 1 which gained a strength of
9.68 MPa. The flexural strength results were average of 3 beams tested. The results of
flexural strength of all mixes are shown in Table 5.5. The flexural strength of different
mixes at 28 days are plotted in Figure 5.6. The flexural strength of different mixes at 56
days are plotted in Figure 5.7.
47
Table 0.4 Flexural Strength
48
10
9
Flexural Strength (MPA)
8
7
6
5
4
3
2
1
0
Mix 1 Mix 2 Mix 3 Mix 4 Mix 5
Mix
10
9
Flexural Strength (MPA)
0
Mix 1 Mix 2 Mix 3 Mix 4 Mix 5
Mix
49
4.2.3 Water Absorption Test
Water absorption test is used to find the water tightness of concrete. It measure the
amount of water that infiltrate in the concrete through pores. The lesser the absorption
more durable the concrete. Water absorption results of different mixes cured for 28 days
are shown in Table 4.5.
Average Absorption
Mix
(%)
Mix 1 2.86
Mix 2 2.66
Mix 3 2.55
Mix 4 2.43
Mix 5 2.21
From the results it is clear that, there is a decrease in the water absorption with the
increase in percentage of bentonite clay replacement which shows that the concrete is
more durable with bentonite. It clearly shows the decrease in the permeability of concrete
and increase in its durability with the addition of bentonite clay as shown in Figure 5.8.
50
3.5
3
Water Absorption (%)
2.5
1.5
0.5
0
Mix1 Mix2 Mix3 Mix4 Mix5
Mix
Figure 4.8 Acid Effect On The Loss Of Weight For Different Mixes
The acid attacks for SCC specimens exposed to sulphuric and hydrochloric acid are
presented below.
Table 0.6 HCL & H2SO4 Avg. Loss Of Weight Of Different Mixes
Mix
5 per cent HCL Acid 5 per cent H2SO4 Acid
51
2.5
1.5
% Weight Loss
0.5
0
Mix 1 Mix2 Mix 3 Mix4 Mix 5
Mix
Figure 4.9 Acid Effect On The Loss Of Weight For Different Mixes
From the results it's far clear that the weight reduction in sulphuric acid become extra
than hydrochloric acid. It's because of the sulphuric acid attack causes considerable
formation of gypsum near the surface, and reasons disintegration mechanical stress which
results in spalling and exposure, due to formation of ettringite. The weight loss in Mix 1
was maximum in each acids which is due to 60 to 65 percentage lime in it, which upon
hydration releases a considerable portion of loose calcium hydroxide which reacts with
acids. Inside the mixes containing bentonite, calcium hydroxide reacts with silica to shape
silica gel in bentonite, hence making bentonite more resistant to acid attacks.
52
4.3 STRESS STRAIN BEHAVIOR OF CYLINDERS UNDER COMPRESSIVE
LOADING
The results of stress strain curve are shown in Figure 4.10. The peak strain and modulus
of elasticity results are tabulated below in Table 4.7.
30
25
20
Stress (MPa)
15
10
0
0 0.002 0.004 0.006 0.008 0.01 0.012 0.014
Strain
53
4.4 COST COMPARISON
Cost comparison of the materials used in this research has been analyzed as per price
purchase from the market. All the mixes were selected for estimation used in this research
work. Let assume casting of a 30m x 40m x 150 mm slab is to be done with and without
replacement of bentonite by cement.
Bentonite= Rs 1/kg
Fine aggregate 73 m3 90 m3
54
CHAPTER 5
5.1 CONCLUSION
Bentonite clay can be effective filler for SCC concrete. It can be directly added to
concrete without much processing. When the fresh properties such as flowability,
passing-ability are considered, 18% of bentonite replacement has given good results.
The compressive strength of SCC specimens increased with the time of curing.
Compressive strength and flexural strength gradually decreases with the replacement of
cement with bentonite by affecting their strength to 24% usage of betonite.
Use of bentonite clay as partial replacement of cement is a cost effective option with
compromising the strength parameters. Water absorption decreased with increase in the
amount of bentonite as cement replacement. Therefore it enhances the durability of
concrete.
SCC utilizing bentonite, as pozzolana is effective in resisting acid attack. However, the
effect of sulfuric acid on concrete is slightly on higher side than hydrochloric acid.
The cost comparison of SCC normal mix vs SCC containing 6% Bentonite as partial
replacement to gain a strength of 25 MPa at age of 28 days age gives 5 percentage
reduction in cost.
5.2 RECOMMENDATIONS
Normal concrete is discussed in this research work. Bentonite used in this research
was in hydrated form it should be calcined at a temperature of 500 ℃ it increases
the rate of reaction with cement. High strength concrete should be studied by
adding admixtures or by using calcined bentonite and by changing the parameters
of mix design.
55
Further durability tests should be conducted. The durability properties of SCC can
be evaluated by varying mix proportions, like cement content, aggregate content,
superplasticizer content, water content and the use of different types and quantity
of filler.
Bentonite as partial replacement of both cement and fine aggregate must be
studied.
Bentonite from other sources then, Jehangira should be evaluated for possible use
as pozzolan.
56
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59